Numerically controlled automatic wiring system

ABSTRACT

A compact, multi-branch, plug-in interconnection module of either two-dimensional or three-dimensional form providing a desired interconnection pattern and having a total effective length related to the sum of the lengths of the individual branches. The interconnection module is fabricated by initially supporting the module terminals in a threading fixture disposed below a threading head which supplies a continuous insulated wire. The fixture is driven in x-y directions by a numerical control positioning apparatus so as to cause the wire from the threading head to thread selected terminals along predetermined paths in a predetermined sequence. After threading, the wires are electrically affixed to the respective terminals to which they were threaded. The resulting structure is then removed from the threading fixture and subjected to a cutting operation which provides for the cutting of wires in all paths except predetermined assigned &#39;&#39;&#39;&#39;threading paths&#39;&#39;&#39;&#39;. The program of the numerical control apparatus is chosen in conjunction with the assignment of the &#39;&#39;&#39;&#39;threading paths&#39;&#39;&#39;&#39; so that the cutting operation results in eliminating all terminal interconnections except those desired in the completed interconnection module. After the cutting operation, the structure is bent into a desired two or three-dimensional shape and then encapsulated leaving its plug-in terminals exposed.

United States Patent.

Alessio et a].

[54] NUMERICALLY CONTROLLED AUTOMATIC WIRING SYSTEM [75] Inventors:Sergio A. Alessio, Elmhurst; Weichien Chow, Park Forrest, both of 111.

[73] Assignee: The Bunker-Ramo Corporation,

Oak Brook, 111.

[22] Filed: May 15, 1970 .[21] Appl. No.: 37,503

[52] US. Cl. ..29/624, 29/604, 29/433 [51] Int. Cl. ..H01b 13/00, H05k3/00 [58] Field of Search ..29/624, 604, 433

[56] References Cited UNITED STATES PATENTS 3,377,699 4/1968 Dinella..29/604 3,391,398 7/1968 Matsushita ....29/604 3,435,518 4/1969 Denes....29/433 3,436,813 4/1969 Wells et al.... ....29/604 3,439,087 4/1969Ledeen ....29/604 3,460,245 8/1969 Hazel et al.... ....29/433 3,543,39712/1970 Hoagland ..29/433 Primary Examiner-John F. Campbell AssistantExaminer-Donald P. Rooney Attorney Frederick M. Arbuckle Jan. 16, 1973 g57 ABSTRACT A compact, multi-branch, plug-in interconnection module ofeither two-dimensional or three-dimensional form providing a desiredinterconnection pattern and having a total effective length related tothe sum of the lengths of the individual branches. The interconnectionmodule is fabricated by initially supporting the module terminals in athreading fixture disposed below a threading head which supplies acontinuous insulated wire. The fixture is driven in x-y directions by anumerical control positioning apparatus so as to cause the wire from thethreading head to thread selected terminals along predetermined paths ina predetermined sequence. After threading, the wires are electricallyaffixed to the respective terminals to which they were threaded. Theresulting structure is then removed from the threading fixture andsubjected to a cutting operation which provides for the cutting of wiresin all paths except predeter mined assigned threading paths. The programof the numerical control apparatus is chosen in conjunction with theassignment of the threading paths" so that the cutting operation resultsin eliminating all terminal interconnections except those desired in thecompleted interconnection module. After the cutting operation, thestructure is bent into a desired two or three-dimensional shape and thenencapsulated leaving its plug-in terminals exposed. I

10 Claims, 6 Drawing Figures 00 00 00!00 0000 00|00 00100 00l00 00 0000'00 00i00 00 00 0000 00 00 00|00 00 00 00/00 0 00 00i00 0000 [ll] DU[ID DU [ll] DU 00 00 00010 00400 15% ,l LR m=: I |,./PATH5---' ll lDUI-[1E] GUIDE] [2 00,00 0000 I 00|00 00|00 0000 0000 I l 00i00 00 00 200 00 00 00 1 00 00 0000 Y 00|00 00|00 NUMERlCAL CONTROL PosmowmeAPPARATUS PATENTED JAN 1 6 I973 SHEET 2 OF 4 'M/I/L'NTORS WICHIN CHOWSERGIO A. ALES/O 5w" A 77OPA/5 v PATENTEUJH 16 I975 SHEET 3 [1F 4wvervrozs WE/CH/EN CHOW .SERG/O A. ALEss/O 5y a Q PATENTEBJAH 16 ms1710.441

sum u 0F 4 WE/CH/EN CHOW 5596/0 A. Amss/o NUMERICALLY CONTROLLEDAUTOMATIC WIRING SYSTEM CROSS-REFERENCES TO RELATED PATENT APPLICATIONSThis patent application is directed to subject matter similar to thatdisclosed in the commonly assigned copending patent application Ser. No.875,906, filed Oct. 12, 1969, for Automated Wiring System and BACKGROUNDOF THE INVENTION It will be recognized that the manner in whichelectronic circuitry is interconnected and packaged is a very importantfactor in the design and construction of electrical apparatus anddevices. The aforementioned patent applications disclose a packaging andinterconnection technique which constitutes a very significant stepforward in this regard.

Briefly, in an exemplary embodiment disclosed in the aforementionedpatent applications, one or more specially constructed interconnectionmodules are plugged into a printed circuit board to provide desiredelectrical interconnections between components thereon. Eachinterconnection module is. typically fabricated using acomputer-controlled winding means for forming wire loops on an elongatedinterconnection module core from a continuous wire in a manner so thatloops are caused to engage predetermined slot locations of the core in apredetermined sequence. Terminals are then provided in the slots and thewire loops electrically affixed thereto, such as by the use ofdipsoldering, infrared bonding or conductive epoxy. The wire loopportions on one side of the core are next removed, such as by cutting orotherwise separating the wires at predetermined locations, whereby theintercohnections provided by the remaining loop portions provide theinterconnection pattern desired for the completed interconnectionmodule. The resulting structure is then encapsulated leaving appropriateterminal portions exposed to serve as plug-in terminals.

OBJECTS AND SUMMARY OF THE PRESENT INVENTION The above describedinterconnection approach of the aforementioned patent application hasthe characteristic that the overall length of the interconnection moduleis dependent on the number of interconnection and/or output terminalsrequired. Accordingly, where a large number of output terminals and/orinterconnections are required, the module may reach an uneconomicallength. For example, a required length of the interconnection module ofgreater than twelve inches may be uneconomical in certain applications.

It is thus the primary object of the present invention to provide animproved construction and fabrication method for an interconnectionmodule which retains the advantages disclosed in the aforementionedpatent application, while overcoming the above described lengthcharacteristic thereof.

Another object of the present invention is to provide an improved,low-cost plug-in type of interconnection module for use with printed andintegrated circuit boards, modules, harness assemblies, and the like,which may be of three-dimensional as well as twodimensional form.

A further object of the present invention is to provide an improvedmethod of making a compact interconnection module having a large numberof terminals. I

Still another object of the present invention is to provide an improvedmethod of making an interconnection module which is economical andcapable of beingautomated to a high degree.

Yet another object of the invention is to providea method of making acompact interconnection module of desired two-dimensional orthree-dimensional form.

Briefly, the above objects are accomplished in a typical embodiment ofthe invention by the provision of a plug-in type of multi-branchinterconnection module having a total effective length related to thesum of the lengths of the individual branches. The interconnectionmodule of the invention is typically fabricated using a technique inwhich the terminals of the module are initially supported in a threadingfixture which, in turn, is driven in an x-y direction by a numericalcontrol positioning apparatus programmed in accordance with the terminalinterconnection pattern desired for the completed module. A fixedthreading head is mounted above the threading fixture and supplies acontinuous wire, whereby x-y movement of the threading fixture inresponse to the numerical control apparatus causes selected terminals tobe threaded along predetermined paths and in a predetermined sequence.After the threading operation, the wires are electrically affixed to therespective terminals to which they have been threaded, following whichthe resulting interconnected terminal structure is removed from thethreading fixture, and the interconnecting wires cut in a manner whichresults in eliminating undesired terminal interconnections, whileretaining desired terminal interconnections. The resulting structure isthen suitably encapsulated, leaving appropriateterminal portions exposedto serve as plug-in terminals for the completed interconnection module.The interconnected terminal structure can be bent and shaped prior toencapsulation so as to permit obtaining an appropriately shapedinterconnection module of three-dimensional form a well as oftwo-dimensional form.

The specific nature of the invention, as well as other objects, uses andadvantages thereof, will become clearly evident from the followingdetailed description of a typical embodiment taken inconjunction withthe accompanying drawings in which:

FIG. 1 is a plan view of an exemplary threading fixture for holdingterminals in place during a numerically controlled threading operation.

FIG. 2 is an enlarged fragmentary perspective view of FIG. 1illustrating details thereof, and showing a wire being threaded betweenselected terminals as a result of x'y movement of the threading fixture.

FIG. 3 is a plan view of the type shown in FIG. 1 which will be used toexplain how wire paths are chosen during the threading operation so thatthe completed interconnection module will provide the desired terminalinterconnections.

FIG. 4 is a schematic plan view illustrating howthe threaded terminalinterconnection structure obtained after threading, soldering, andremoval from the threading fixture may typically be cut alongpredetermined lines to eliminate undesired terminal interconnections,while retaining desired terminal interconnections.

FIGS. 5 and 6 are perspective views illustrating two possible shapesthat can be provided for the completed interconnection module.

Like numerals refer to like elements throughout the figures of thedrawings.

Referring initially to FIGS. 1 and 2, illustrated therein is a typicalthreading fixture 10 having a base 11 and perpendicularly projectingplugs 12 and 13 for holding banks of electrical terminals 15 during athreading operation. For greater clarity, the spacings between thevarious groups of plugs in FIG. 1 have been exaggerated and terminalsare shown residing in only the lower-left group of plugs.

The base 11 of the fixture 10 may typically be of aluminum, while thethreading plugs 12 and 13 may typically be nylon plugs plugged intosuitable receiving holes (not shown) in the base 11. The dimensions ofthe base 11 may, for example, be 8 X 10 X 7% inches, and each plug 12 or13 may, for example, have dimensions of 0.3 X 0.1 X 0.05 inch.

As best seen in FIG. 2, each terminal 15 is provided with spaced,perpendicularly depending crimping members 15a which are used aftercompletion of the threading operation to secure any wires which havebeen threaded thereto. As also best seen from FIG. 2, the terminals 15are held in respective spaces (for example, 0.1 inch) between adjacentlike-numbered plugs 12-.12 or 13-13 with their crimping members 150being seated in smaller spacings (for example, 0.04 inch) providedbetween each pair of plugs 12-13.

It will be seen from FIG. 2 that the threading head 25 has a wirefeeding end 25a for supplying a continuous insulated wire to thethreading fixture 10. The location of the wire feeding end a of thethreading head 25 with respect to the plugs 12, 13 and the forcerequired to pull out the wire 20 therefrom are chosen so that, duringthe threading operation, the wire 20 is spewed out to interconnectpredetermined ones of the terminals 15 along predetermined paths incorrespondence with the x-y movement of the fixture 10 dictated by thenumerical control apparatus l8.

Reference is now additionally directed to the exemplary threadingarrangement illustrated in FIG. 3 for use in explaining how thepathstraversed by the wire 20 during a threading operation are chosen inorder to provide the terminal interconnections desired for the completedinterconnection module. For simplicity and clarity,on'ly the particularplugs 12 and 13 ofthe fixture 10 are shown which hold the terminals thatare threaded by the wire 20 in the exemplary threading arrangementillustrated, these particular terminals being designated by the lettersA, B, C, D, E, F and G for identification purposes. Also, it will beunderstood that the exemplary threading arrangement illustrated in FIG.3 normally constitutes only a relatively small portion of a completedthreading arrangement which typically may have many overlapping wirepaths with many wires in each path and with one or more wires threadingeach terminal. In addition, it will be assumed in connection with theexemplary threading arrangement of FIG. 3 that the completedinterconnection module requires interconnections only between the pairsof terminals A and B, C and D, E and F, and G and H. i

The illustrative threading arrangement shown in FIG. 3 for thecontinuous wire 20 will be seen to begin at the lower left group ofplugs 12, 13 holding terminal A, and from there progresses tosequentially thread the plugs 12, 13 corresponding to terminals B, C, D,E, F, G and H via the particular paths shown. Although all of theterminals A to H are thus interconnected by the same wire 20, thepresent invention nevertheless permits the desired terminalinterconnections to be obtained for the completed module. This isachieved as a result of having assigned certain threading paths to thefixture 10, such as, for example, the threading paths illustrated inFIG. 1. Wires contained in these threading paths are retained duringsubsequent fabrication operations performed on the module, while wiresin all other possible paths are cut. Thus, as the wire 20 proceeds fromterminal to terminal during the threading operation, terminals which areto be electrically interconnected in the completed module are intercon-I nected via one or more threading paths, while terminals which are notto be electrically connected are interconnected via at least one pathwhich is not a threading path. Accordingly, the pairs of terminals A andB, C and D, E and F, and G and H between which electrical connectionsare desired are each interconnected only via one or more of thethreading paths illustrated in FIG. 1, while each of the pairs ofterminals B-C, D-E and F-G are interconnected via at least one pathwhich is not a threading path". Obviously, the invention is not limitedto the particular exemplary threading paths" illustrated in FIG. 1.

After the threading operation is completed, the crimping members 15a ofthe terminals 15 (FIGS. 1 and 2) are crimped to secure the wires to therespective terminals to which they were threaded. This can beaccomplished for each terminal individually or, preferably, by the useof a suitable crimping fixture (not shown) which is applied over thethreading fixture 10 for performing the crimping operation on allterminals simultaneously. The wires are then soldered to theirrespective terminals, such as by the use of infrared soldering or othersuitable means.

The next step in the fabrication of the interconnecti n module is toremove the resulting soldered interconnected terminal structure from thethreading fixture, and to'then cut the wires in all interconnectionpaths 'except the threading paths illustrated in FIG. 1. A typicalmanner in which this cutting may be accomplished is illustrated in FIG.4 by the x cutting lines indicated therein, which results in amulti-branch interconnected-terminal structure having the form of an H-corresponding to that of the threading paths of FIG. 1. While thecutting of these wires could, of course, be done in a plurality ofsteps, it is preferred that this cutting be done simuleaneously, suchas, for example, by the application to the structure of a cuttingfixture (not shown) having cutting edges corresponding to thecuttinglines indicated in FIG. 4.

The final steps in the fabrication of the interconnection module involvebending the terminals to the final positions desired for the completedintei-connection module, then electrically. isolating the individualterminals, such as by cutting each terminal bank along the dashed line27 in FIG. 1, and then suitably encapsulating the entire interconnectedterminal structure to provide the resulting interconnection moduletypically illustrated in FIG. 5 which typically may have overalldimensions of 3 X 3 X 1% inches.

It will be understood that, since the interconnected terminal structureis capable of being bent in various ways prior to encapsulation, a widevariety of shapes of either two-dimensional or three-dimensional formmay be provided for the completed interconnection module. FIG. 6illustrates a particular three-dimensional shape which may be providedfor the completed interconnection module by bending each of the outerlegs of the structure outwardly by an angle of 90 prior toencapsulation.

The interconnection module in accordance with the invention may be usedfor a wide variety of purposes, such as a plug-in module for a printedcircuit board for interconnecting integrated circuit modules and/orother components or connectors provided thereon, and/or may also be usedwith a mother board for interconnecting other printed circuit boards.Also, a module in accordance with the invention may be adapted forsoldering to a printed circuit board, or the module terminals could beemployed as the contacts of a connector. The interconnection module ofthe invention may additionally be adapted so as to be capable of beingplugged intothe connector terminals of a harness assembly for providingdesired interconnections between the wires of the harness. The aboveexamples of possible uses are obviously not exhaustive, and variousother uses will, no doubt, occur to those skilled in the art.

Although the present invention has been described in connection withparticular exemplary embodiments thereof, it is to be understood thatthe invention is subject to many modifications in construction,arrangement, method of fabrication and use without departing from thescope of the invention as defined in the appended claims.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as fol-- lows:

1. In a method of providing a desired terminal inter connection pattern,the steps of:

. providing terminal supporting means having terminals disposed atpredetermined locations thereof,

automatically threading selected terminals with a continuous wire in apredetermined order and following selected paths such that thoseterminals which are to be electrically connected are interconnected onlyvia predetermined threading paths while thoseterminals which are not tobe electrically connected are interconnected via at least one path whichis not one of said predetermined threading paths, and

cutting the threaded wires in all but said predetermined threading pathsso as to thereby provide the desired terminal interconnection patternfor said module.

2. The invention in accordance with claim I,

wherein said method includes affixing the threaded wires to therespective terminals 'to which they are threaded prior to said cutting.

3. The invention in accordance with claim 2,

wherein said method includes removing from said supporting means theresulting terminal and threaded wire structure obtained after saidcutting and then encapsulating the structure leaving at leastpredetermined ones of said terminals exposed.

4. The invention in accordance with claim 3,

wherein said method includes bending said structure into a desired shapeprior to encapsulation. 5; In a method of making an interconnectionmodule having a desired terminal interconnection pattern, the steps of:

supporting module terminals at predetermined locations of a supportingmeans disposed adjacent a threading head which supplies a continuouswire,

relatively moving said supporting means and said threading head underthe control of a numerical control apparatus so as to thread selectedterminals in a manner such that those terminals which are to beelectrically connected in said module are interconnected only viapredetermined threading paths while those terminals which are not to beelectrically connected are interconnected via at least one path which isnot one of said predetermined threading paths,

affixing the threaded wires to the respective terminals to which theyare threaded, and

cutting the threaded wires along predetermined cutting lines so thatwires in all but said predetermined threading paths are cutso as tothereby pro vide the desired terminal interconnection pattern for saidmodule.

6. In a method of fabricating an electrical circuit said predeterminedprogram being chosenin accordance with the interconnection patterndesired for said module so that those members corresponding to terminalsbetween which electrical connections are desired are threaded via firstpredetermined paths while those members corresponding to terminalsbetween which electrical connections are not desired are threaded viasecond predetermined paths different from said first predeterminedpaths, and

cutting said threaded structure along paths intersecting said secondpredetermined paths so that wires located in said second predeterminedpaths are cut while wires located in said first predetermined paths areretained, thereby providing a resulting electrical interconnectionpattern for said threaded structure conforming to that desired for saidmodule. a

7. The invention in accordance with claim 6, wherein said methodincludes affixing terminals to said threaded structure at locationsthereof corresponding to the locations of said threading members.

8. The invention in accordance with claim 7, wherein said methodincludes removing said threaded structure from 1 said fixture andbending said structure into a desired shape.

9. The invention in accordance with claim 7, wherein said terminals areinitially disposed in said threading members of said fixture prior tothe formation-of said

1. In a method of providing a desired terminal interconnection pattern,the steps of: providing terminal supporting means having terminalsdisposed at predetermined locations thereof, automatically threadingselected terminals with a continuous wire in a predetermined order andfollowing selected paths such that those terminals which are to beelectrically connected are interconnected only via predeterminedthreading paths while those terminals which are not to be electricallyconnected are interconnected via at least one path which is not one ofsaid predetermined threading paths, and cutting the threaded wires inall but said predetermined threading paths so as to thereby provide thedesired terminal interconnection pattern for said module.
 2. Theinvention in accordance with claim 1, wherein said method includesaffixing the threaded wires to the respective terminals to which theyare threaded prior to said cutting.
 3. The invention in accordance withclaim 2, wherein said method includes removing from said supportingmeans the resulting terminal and threaded wire structure obtained aftersaid cutting and then encapsulating the structure leaving at leastpredetermined ones of said terminals exposed.
 4. The invention inaccordance with claim 3, wherein said method includes bending saidstructure into a desired shape prior to encapsulation.
 5. In a method ofmaking an interconnection module having a desired terminalinterconnection pattern, the steps of: supporting module terminals atpredetermined locations of a supporting means disposed adjacent athreading head which supplies a continuous wire, relatively moving saidsupporting means and said threading head under the control of anumerical control apparatus so as to thread selected terminals in amanner such that those terminals which are to be electrically connectedin said module are interconnected only via predetermined threading pathswhile those terminals which are not to be electrically connected areinterconnected via at least one path which is not one of saidpredetermined threading paths, affixing the threaded wires to therespective terminals to which they are threaded, and cutting thethreaded wires along predetermined cutting lines so that wires iN allbut said predetermined threading paths are cut so as to thereby providethe desired terminal interconnection pattern for said module.
 6. In amethod of fabricating an electrical circuit module having a plurality ofoutput terminals electrically interconnected in a predeterminedelectrical interconnection pattern, the steps of: disposing a wirethreading head adjacent a threading fixture having a plurality ofthreading members at locations corresponding to said output terminals,automatically moving said head and said fixture relative to one anotherso that said members are threaded by a continuous wire supplied by saidhead in an order and along paths in accordance with a predeterminedprogram so as to produce a threaded wire structure containing bothdesired and undesired electrical connections, said predetermined programbeing chosen in accordance with the interconnection pattern desired forsaid module so that those members corresponding to terminals betweenwhich electrical connections are desired are threaded via firstpredetermined paths while those members corresponding to terminalsbetween which electrical connections are not desired are threaded viasecond predetermined paths different from said first predeterminedpaths, and cutting said threaded structure along paths intersecting saidsecond predetermined paths so that wires located in said secondpredetermined paths are cut while wires located in said firstpredetermined paths are retained, thereby providing a resultingelectrical interconnection pattern for said threaded structureconforming to that desired for said module.
 7. The invention inaccordance with claim 6, wherein said method includes affixing terminalsto said threaded structure at locations thereof corresponding to thelocations of said threading members.
 8. The invention in accordance withclaim 7, wherein said method includes removing said threaded structurefrom said fixture and bending said structure into a desired shape. 9.The invention in accordance with claim 7, wherein said terminals areinitially disposed in said threading members of said fixture prior tothe formation of said threaded structure during the step ofautomatically moving.
 10. The invention in accordance with claim 7,wherein said fixture has a planar surface from which said threadingmembers depend, and wherein the relative movement of said head andfixture during the step of automatically moving occurs in directionsparallel to said planar surface.